Prefabricated wall panel with tongue and groove construction

ABSTRACT

A prefabricated wall panel has a precast body including at least one decorative design element. In addition, the wall panel includes a mounting element having a first end embedded in the precast body and a second end projecting from the precast body. A groove is formed between the precast body and the second end of the mounting element along a first edge of the precast body. A tongue is formed along a second edge of the precast body opposite the first edge. The tongue and groove cooperate to allow prefabricated wall panels to be more easily installed on a support substrate.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. application Ser.No. 14/879,827, entitled “Prefabricated Wall Panel with Tongue andGroove Construction,” filed Oct. 9, 2015, and issued as U.S. Pat. No.9,903,124 on Jul. 22, 2014, which is a continuation application of U.S.application Ser. No. 14/299,250, entitled “Prefabricated Wall Panel withTongue and Groove Construction,” filed Jun. 9, 2014, and will be issuedas U.S. Pat. No. 10,329,775 on Jun. 25, 2019, which is a divisionalapplication of U.S. application Ser. No. 12/026,876, entitled“Prefabricated Wall Panel with Tongue and Groove Construction,” filedFeb. 6, 2008, and issued as U.S. Pat. No. 8,782,988 on Jul. 22, 2014,the contents of which are herein incorporated by reference in theirentirety.

TECHNICAL FIELD

This invention relates generally to the construction field and, moreparticularly, to a prefabricated wall panel incorporating a mountingelement.

BACKGROUND OF THE INVENTION

Prefabricated or cast veneer wall panels have been developed as a quickand efficient way to provide a masonry appearance for a building whilesimplifying construction and lowering construction cost. The designelements of prefabricated wall panels typically simulate brick, stone,tile and other masonry building components or materials commonly used inthe construction of buildings. Examples of prefabricated wall panels aredisclosed in U.S. Pat. No. 3,142,938 to Eberhardt, U.S. Pat. No.4,669,238 to Kellis et al, U.S. Pat. No. 5,379,561 to Saito and U.S.Pat. No. 5,673,529 to Treister et al, in published U.S. PatentApplication Serial No. 2007/0137128 to Viau et al and in Co-pendingpatent application Ser. No. 11/647,751 owned by the Assignee of thepresent invention.

Prefabricated wall panels are typically made from reinforcedconstruction materials such as fiberglass reinforced concrete.Prefabricated wall panels made from such reinforced materials areresistant to damage to handling during packaging, shipping andinstallation. However, further improvements in durability to decreaseloss due to breakage are still desired. The present invention relates toa prefabricated wall panel incorporating a mounting element to enhancedurability and provide significantly improved handling characteristicsas well as tongue and groove construction to simplify installation.

BRIEF SUMMARY

In accordance with the purposes of the present invention as describedherein, an improved prefabricated wall panel is provided. Theprefabricated wall panel comprises a precast body including at least onedecorative design element and a mounting element including a first endembedded in the precast body and a second end projecting from theprecast body. The wall panel includes at least one protrusion and atleast one keying hole in the mounting element. The protrusion may takethe form of a dimple and have an interior diameter of betweenapproximately 0 and approximately 7.6 centimeters and a depth of betweenapproximately 0.30 and approximately 0.35 centimeters. An aperture isprovided in the dimple. The aperture has a diameter of about 0.3175centimeters and is concentrically positioned in the dimple. In addition,the wall panel includes at least one weep hole in the mounting element.

In one possible embodiment, the wall panel includes a groove formedbetween the precast body and the second end of the mounting elementalong a first edge of the precast body. In addition, a tongue is formedalong a second edge of the precast body opposite the first edge. Thattongue is formed by the precast body. The tongue is sized and shaped tobe received in the groove so that prefabricated wall panels of thepresent invention may be vertically stacked and interconnected to form awall.

The first end of the mounting element extends in a first plane and thesecond end of the mounting element extends in a second plane wherein thesecond plane is parallel to the first plane. The mounting elementfurther includes a transition section that connects the first end to thesecond end and transitions between the first and second planes. In onepossible embodiment the wall panel includes multiple decorative designelements and the groove is provided behind at least one of the multipledecorative design elements.

In accordance with an additional aspect of the present invention themounting element is made from a material selected from a groupconsisting of metal, plastic, steel, corrosion resistant steel,aluminum, stainless steel, zinc, copper and combinations thereof. Themounting element is formed as a solid sheet, as a mesh or as acombination of solid sheet and mesh.

The precast body is made from a material selected from a groupconsisting of concrete, fiber reinforced concrete, gypsum, othercementitious materials and mixtures thereof The precast body includesreinforcing fibers selected from a group of fibers consisting of glassfibers, mineral fibers, natural fibers, polymer fibers, E-glass fibers,AR-glass fibers and mixtures thereof.

In another possible embodiment, the wall panel includes a slot formed inthe second end of the mounting element and a tab projecting from asecond edge of the precast body opposite the first edge. The tab isformed by the mounting element. The mounting element may be one piececonstruction or two piece construction. In one embodiment the mountingelement is at least one piece, in yet another embodiment the mountingelement is at least two pieces. In one possible embodiment the mountingelement is a solid body. In another possible embodiment at least aportion of the mounting element is mesh.

The tab is sized and shaped to be received in the slot so thatprefabricated wall panels of the present invention may be interconnectedto form a wall. The first end of the mounting element extends in a firstplane, the second end of the mounting element extends in a second planeand the tab of the mounting element extends in a third plane between thefirst and second planes. In addition, the slot is provided in atransition section that connects the first and second ends of themounting element. That slot also rests in the third plane.

In accordance with yet another aspect of the present invention a methodis provided for forming a wall panel in a mold having a mold cavity. Themethod comprises the steps of: (a) positioning a mounting element with afirst end extending into the mold cavity and a second end extending fromthe mold cavity; (b) adding casting material into the mold cavity so asto embed the first end of the mounting element in the casting material;(c) forming a tongue in the mold cavity from casting material capturedunder a dimensional flap; (d) forming a groove in the mold between thecasting material and the first end of the mounting element; (e) allowingthe casting material to set; and (f) removing the wall panel from themold. The method may also include adding casting material to the moldabove a lower most surface of the dimensional flap. In addition, themethod may include stretching the mold to free the tongue from under thedimensional flap while removing the wall panel from the mold.

In accordance with yet another aspect of the present invention, a moldis provided for forming a wall panel. The mold comprises a bodyincluding a mounting element support surface and a mold cavity. The bodyfurther includes a dimensional flap overlying a portion of the moldcavity. Still further, the mounting element support surface of the moldis provided along a first edge of a mold cavity and the dimensional flapis provided overlying a second edge of the mold cavity wherein the firstedge is opposite the second edge.

In the following description there is shown and described severaldifferent embodiments of the invention, simply by way of illustration ofsome of the modes best suited to carry out the invention. As it will berealized, the invention is capable of other different embodiments andits several details are capable of modification in various, obviousaspects all without departing from the invention. Accordingly, thedrawings and descriptions will be regarded as illustrative in nature andnot as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated herein and forming a part of thespecification, illustrate several aspects of the present invention andtogether with the description serve to explain certain principles of theinvention. In the drawings:

FIG. 1 is a front perspective view of the prefabricated wall panel ofthe present invention;

FIG. 2 is a cross-sectional view of the prefabricated wall panelillustrated in FIG. 1;

FIG. 3 is a partially schematical and cross sectional view illustratingthe mounting of two wall panels, one above the other, along a supportsubstrate such as a wall stud;

FIGS. 4A-4D are fragmentary front elevational views of four differentmounting elements used in the prefabricated wall panel of the presentinvention;

FIGS. 5A-5G are schematical sectional views illustrating severaldifferent embodiments of the wall panel of the present invention; and

FIG. 6 is a cross sectional view of the mold in which the wall panel ofFIGS. 1 and 2 are formed.

Reference will now be made in detail to the present preferredembodiments of the present invention examples of which are illustratedin the accompanying drawings.

DETAILED DESCRIPTION

Reference is now made to FIG. 1 illustrating the prefabricated wallpanel 10 of the present invention. Such a wall panel 10 may be used as awall cladding for a building. Further applications include but are notlimited to the construction of a fireplace surround or an outdoor livingcomponent such as a decorative wall or grill surround.

The prefabricated wall panel 10 comprises a precast body 12 including atleast one decorative design element 14. As illustrated the designelement 14 comprises two rows of overlapping brick with four brick ineach row. It should be appreciated that substantially any other masonrymaterial known in the art may be simulated including bricks of differentsizes, stones of the same or different sizes and shapes, tiles ofdifferent sizes and shapes and the like.

The precast body 12 is made from a cast material such as concrete,reinforced concrete, gypsum, fiber reinforced gypsum, polymer modifiedgypsum, reinforced cementitious material and mixtures thereof. Typicallythe cast material reinforcement comprises fibers selected from a groupof materials consisting of glass fibers, carbon fibers, mineral fibers,natural fibers, polymer fibers and mixtures thereof. Where glass fibersare used they are typically of the E-glass or AR-glass type whichexhibits some alkali resistance.

As best illustrated in FIGS. 1 and 2, the prefabricated wall panel 10also includes a mounting element, generally designated by referencenumeral 16. The mounting element 16 may be made from a material selectedfrom a group consisting of wood, concrete, cellulose fiber board,polymer material, composite material, metal, plastic, reinforcedplastic, thermoplastic, fiber composite, reinforced wood, steel,corrosion-resistant steel, aluminum, stainless steel, zinc, copper andcombinations thereof. The corrosion-resistant steel may take any numberof forms including, but not limited to, galvanized, galvanneal,Gavalume™ brand, tin coating, chromium coating, nickel coating,phosphorous coating, magnesium coating, copper coating, zinc coating,weathering steels (i.e., alloys of steel with small additions of copper,aluminum, nickel and/or phosphorous), polymer coatings and paint.

Polymer materials useful for the making of the mounting element 16include various thermoplastic and thermoset resins including but notlimited to polyolefins, polyesters, polyvinylchloride, polypropylene,polyethylene, polyamide, epoxy, vinyl ester, acrylic, polystyrene, ABS,melamine and mixtures thereof. Composite materials used to make themounting element 16 include a reinforcing material and a matrix binder.Appropriate reinforcing materials useful in the present inventioninclude but are not limited to glass fibers, natural fibers, mineralfibers, basalt fibers, carbon fibers, kenaf fibers, jute fibers, hempfibers, E-glass fibers, C-glass fibers, R-glass fibers, S-glass fibers,ECR-glass fibers, AR-glass fibers and mixtures thereof. It should beappreciated that substantially any type of glass fiber may be used forreinforcement fibers. Glass fibers appropriate for use in the presentinvention may be loose chopped strand or glass mat and include thoseavailable under the trademark ADVANTEX. Matrix binder materials usefulfor this purpose include but are not limited to polyolefins, polyesters,polyvinylchloride, polypropylene, polyethylene, polyamide, epoxy, vinylester and mixtures thereof.

As best illustrated in FIG. 2, the mounting element 16 includes a firstend 18 that is embedded in the precast body 12 and a second end 20 thatprojects from the precast body. This may be accomplished by positioningthe mounting element 16 so that the first end 18 projects into the moldcavity in which the body 12 is cast. After positioning the mountingelement 16, the cast material is sprayed, injected or otherwise added tothe mold. The cast material of the body 12 covers the front and the rearmajor faces of the first end 18 of the mounting element 16. When set,the body 12 securely holds the mounting element 16 in position.Typically, the first end 18 includes a series of spaced keying holes 17.These holes 17 fill with the cast material and ensure that the mountingelement 16 is firmly seated and secured in the cast body 12 once thematerial sets.

As illustrated in FIGS. 1 and 2, the second end 20 of the mountingelement 16 projects upwardly from the top edge of the precast body 12.In the illustrated embodiment, the mounting element 16 includes atransition section 22 connecting the first end 18 with the second end20. In one embodiment, the transition section 22 forms an included angleof between 0° and about 180°. In another embodiment, as illustrated inFIG. 2, the transition section 22 forms an included angle of betweenabout 130° and about 140° and most typically 135° with the first end 18.

As further illustrated in FIG. 1, the second end 20 of the mountingelement 16 may include a series of protrusions 21. The protrusion 21 maytake the form of dimples, slots, ribs or any other structure thatprovides a set back means and can receive a nail or fastener. In theillustrated embodiment, the protrusion 21 is a dimple. The dimples 21project away from the front face 28 of the wall panel 10. The dimples 21function to provide an air space A between the wall panel 10 and thesheathing S or other building substrate to which the wall panel 10 isfastened. The wall panel 10 is fastened or secured to the sheathing S bymeans of fasteners such as nails or screws F (see FIGS. 2 and 3) thatare received and pass through the recessed apertures 23 provided alongthe second end 20 of the mounting element 16.

Typically, each dimple 21 has an interior diameter of betweenapproximately 0 and approximately 7.6 centimeters. More typically, eachdimple 21 has an interior diameter of between about 2.5 and about 7.6centimeters. Still more typically each dimple 21 has an interiordiameter of between about 2 to about 5 centimeters. For manyapplications, each dimple 21 has an interior diameter of between about1.0 and about 1.6 centimeters.

Each dimple also has a depth of between approximately 0.30 andapproximately 0.60 centimeters. The aperture 23 in each dimple 21typically has a diameter of about 0.3175 centimeters. Further, theaperture 23 is concentrically received in the bottom of the dimple 21.Advantageously, the diameter of the dimple 21 allows the head of afastener, such as a roofing nail, to fit inside the dimple where it willnot interfere with the mounting of the next panel. The aperture 21insures the centering of the nail in the dimple. The bottom wall of thedimple 21 is also slightly curved as illustrated. The size and shape ofthe dimple 21 insures that the dimple does not collapse or becomeembedded in the underlying sheathing during installation of the wallpanel 10. In this way good ventilation is insured between the wall paneland the underlying sheathing to which it is mounted as discussed indetail below.

In order to complete a wall, it is necessary to vertically stack aseries of prefabricated wall panels 10. Each additional row of wallpanels 10 is offset with respect to the previous row by the staggeredends 34 provided on the panels in a manner well known in the art. Aseach succeeding wall panel 10 in each succeeding row is added (see FIGS.2 and 3), a tongue and groove arrangement ensures proper placement andgreatly simplifies installation.

More specifically, each wall panel 10 includes a groove 36 formedbetween the precast body 12 and the front face of the second end 20 ofthe mounting element 16. The groove 36 is provided in or along the firstor top edge 38 of the precast body 12. In the illustrated embodiment, acooperating tongue 40 is formed by the second or bottom edge of theprecast body 12. In alternative embodiments, the tongue 40 could beformed by a metal backer or other similar structure. Duringinstallation, the tongue 40 on one wall panel 10 is precisely sized andshaped to be received in the cooperating groove 36 on the underlyingwall panel 10. This interconnection ensures proper registration betweenwall panels 10 during installation. Further, the tongue and grooveconnection between the wall panels 10 functions to support the wallpanel being added in proper position until fasteners F can be positionedin the support substrate S through the recessed apertures 21 to hold thepanel in place. Grout is then provided in the grout areas 32 between thedesign elements 14 on all of the wall panels 10 in order to complete theinstallation. Weep holes 25 are provided at spaced locations in thesecond end 18 of the mounting element 16 adjacent the transition section22. These weep holes 25 allow water to drain from the groove 36. In theillustrated embodiment, a weep hole 25 is provided at the center of eachbrick design element 14. In another embodiment, the weep hole 25 may notbe at the center of each brick design element 14.

As best illustrated in FIGS. 4A-4D, the mounting element 16 may take anumber of forms. As illustrated in FIGS. 1, 2, 3 and 4A, the first end18 and second end 20 may both be made from a solid piece of material.Alternatively, as illustrated in FIG. 4B, the two ends 18, 20 may bothbe made from a mesh material (i.e. any perforated material), such as,galvanized steel, aluminum and/or copper. As yet another alternative,FIG. 4C illustrates an embodiment wherein the first end 18 is made froma mesh material and the second end 20 is made from a solid material. Incontrast, FIG. 4D illustrates an embodiment where the first end 18 ismade from a solid material and the second end 20 is made from a meshmaterial.

The use of mesh material instead of solid material serves a number ofadvantages. Good strength is obtained yet less material is used therebyreducing costs of production. Where the first end 18 is made of meshmaterial, the interlocking of the mounting element 16 in the precastbody 12 is enhanced. This is because the cast material is received inand passes through each of the openings in the mesh to provide a mostsecure interconnection.

Alternative embodiments for the wall panel 10 are illustrated in FIGS.5A-5G. In FIG. 5A, the first end 18 of the mounting element 16 is longenough to extend nearly to the end of the tongue 40. This provides addedstrength to the precast body 12. In this embodiment, the first end 18 ofthe mounting element 16 is made from solid material including a fewspaced keying holes 17 for receiving cast material. In the embodimentillustrated in FIG. 5B, the first end 18 is made from mesh material.

FIG. 5C illustrates a wall panel 10 incorporating a mounting element 16with a second end 20 constructed from mesh material and an extendedfirst end 18 constructed from solid material but incorporating severalkeying holes 17. FIG. 5D illustrates yet another alternative embodimentwherein the entire mounting element 16 is made from mesh materialincluding the first end 18.

FIGS. 5E-5G illustrate additional alternative embodiments. In FIG. 5E,the mounting element 16 is made from two separate pieces (NOTE: It couldbe made of three, four or more pieces if desired). The first piece 16 aof the mounting element includes a first end 18 embedded in the precastbody 12 and extending in a first plane P₁, a second end 20 projectingfrom the precast body 12 and extending in a second plane P₂ and atransition section 22 connecting the first and second ends 18 and 20. Asfurther illustrated, the first end includes a keying hole 17 thatreceives the cast material to ensure that the first piece of themounting element 16 a is securely held in position by the precast body.The second end 20 includes at least one dimple 21 as described above. Inaddition, the transition section 22 includes a slot 70.

As further illustrated in FIG. 5E, a second mounting element 16 b formsa tab 72 projecting from a second edge of the precast body 12. Thesecond piece of the mounting element 16 b, like the first piece of themounting element 16 a, includes a keying hole 17 to receive castmaterial and insure it is securely held in the precast body 12. Asillustrated, the slot 70 and the tab 72 both extend in a third plane P₃between the first and second planes P₁P₂. Accordingly, a second wallpanel 10 may be added to a first wall panel 10 previously secured to asubstrate by aligning and inserting the tabs 72 on the second wall panelinto the slots 70 on the first wall panel. Thus, the slots and tabs 70,72 function like the tongue and grooves 40, 36 on the embodiments inFIGS. 1 and 2 to align and secure wall panels 10 together.

FIG. 5F shows yet another alternative embodiment of the slot and tab 70,72 construction. In this embodiment the mounting element 16 is a singlepiece incorporating a series of keying holes 17 to allow it to be firmlysecured in the precast body 12. This single piece mounting element 16provides additional strength to the precast body 12.

In the additional embodiment illustrated in FIG. 5G, a single piecemounting element 16 is again illustrated incorporating the slot 70 andgroove 72 connection system. Unlike the embodiment illustrated in FIG.5F, in the embodiment illustrated in FIG. 5G, a portion 74 of themounting element 16 embedded in the precast body 12 is made from a meshmaterial.

A mold 50 for forming a wall panel 10 is illustrated in FIG. 6. The mold50 comprises a mold body 52 formed from an elastomeric material such assilicone, urethane, polyurethane, and/or latex. The mold body 52includes a mounting element support surface 54, a mold cavity 56 and adimensional flap 58 overlying a portion of the mold cavity that formsthe tongue 40. Sufficient casting material may be added to the mold 50above a lowermost surface 39 of the dimensional flap 58 to insure thegroove 36 is formed to proper shape. More specifically, the mountingelement support surface 54 is provided along a first edge 60 of the moldcavity 56 while the dimensional flap 58 is provided along a secondopposite edge 62 of the mold cavity.

The wall panel 10 is produced by positioning a mounting element 16 ontothe support surface 54 with the first end 18 extending into the moldcavity 56 and the second end 20 extending from the mold cavity. Castingmaterial may be added to the mold cavity 56 before and/or afterpositioning the mounting element 16 onto the support surface 54. Thismay be done by injecting, spraying or any other means known in the art.During this step, the first end 18 of the mounting element 16 isembedded in the casting material.

The method also includes the step of forming the tongue 40 in the moldcavity 56 from casting material captured under the dimensional flap 58.Still further, the method includes forming the groove 36 in the mold 50between the precast body 12 and the second end 20 of the mountingelement 16. After allowing the cast material to set, the wall panel 10is removed from the mold 50. This may be done by stretching the moldbody 52 to free the tongue 40 from under the dimensional flap 58.

The foregoing description of the preferred embodiments of the presentinvention have been presented for purposes of illustration anddescription. It is not intended to be exhaustive or to limit theinvention to the precise form disclosed. Obvious modifications orvariations are possible in light of the above teachings. For example, inthe illustrated embodiments, the apertures 23 for receiving a fastenerare provided in the protrusion 21. In alternative embodiments, suchapertures 23 may be provided substantially anywhere in the body 12. Asanother example, the illustrated embodiment of FIG. 5E includes amounting element 16 with a first end 18 extending in a first plane P₁and a second end 20 extending in a second plane P₂ where the planes P₁and P₂ are parallel to one another. The mounting element 16 couldinclude ends that extend in planes that are not parallel to one another.

The embodiments were chosen and described to provide the bestillustration of the principles of the invention and its practicalapplication to thereby enable one of ordinary skill in the art toutilize the invention in various embodiments and with variousmodifications as are suited to the particular use contemplated. All suchmodifications and variations are within the scope of the invention asdetermined by the appended claims when interpreted in accordance withthe breadth to which they are fairly, legally and equitably entitled.The drawings and preferred embodiments do not and are not intended tolimit the ordinary meaning of the claims in their fair and broadinterpretation in any way.

The invention claimed is:
 1. A panel comprising: a body comprising afront surface that includes a design element and a rear surface, thebody having a bottom edge and a top edge, wherein the body comprisesconcrete; and a mounting element formed of metal and projecting from thebody, the mounting element comprising a first end portion extendingabove the top edge of the body and a second end portion embedded withinthe body, wherein the first end portion of the mounting elementcomprises a plurality of protrusions in the form of dimples spaced alonga length of the first end portion and configured to provide spacingbetween adjacent dimples, each dimple configured to receive acorresponding nail or fastener and having a diameter configured toreceive a head of each corresponding nail or fastener; wherein thedimples serve as a set back feature configured to provide spacingbetween the rear surface of the body and a supporting wall on which thepanel is configured to be installed.
 2. The panel of claim 1, whereinthe first end portion, the second end portion, or both, of the mountingelement extends parallel to a plane that includes the rear surface. 3.The panel of claim 1, wherein the mounting element comprises openingsconfigured to allow water to pass therethrough.
 4. The panel of claim 1,wherein the mounting element further comprises a plurality of keyingholes spaced along a length of the body.
 5. The panel of claim 1,wherein: the mounting element comprises a transition portion thatextends between the first end portion and the second end portion,wherein the first portion extends within a first plane and includes theplurality of protrusions, the second end portion extends within a secondplane, and the transition portion extends within a third plane, and thethird plane intersects the first and second planes at an angle.
 6. Thepanel of claim 5, wherein an opening is defined in the transitionportion.
 7. The panel of claim 1, wherein the mounting element comprisesa tab portion projecting from an edge of the body and configured to bereceived in a slot of another panel mounted on the supporting wallrelatively adjacent thereto.
 8. The panel of claim 1, wherein thedimples are arranged in a single row of at least four dimples spacedalong the length of the first end portion of the mounting element. 9.The panel of claim 1, wherein a surface of the mounting elementsurrounding each dimple is planar.